Tools Required

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.

1. Lock the steering column by installing J 42640 into the underside of the steering column.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5L.

Important: Remove both the throttle and the cruise control cables in order to prevent kinking of the cables during lowering of the transaxle.




4. Remove both the throttle and the cruise control cables (1) from the throttle body and the accelerator control bracket (2).



5. Use a large flat-bladed tool in order to remove the range selector cable from the range selector lever.
6. Remove the range selector cable bracket from the transmission case and set aside.



7. Remove nut (5) and bolt (2) from AIR pipe.



8. Remove bolt (3) from AIR pipe (2).
9. Remove the ground cable bolt (1) from the transaxle.



10. Disconnect the transaxle electrical connector C100 (2).
11. Disconnect the wiring harness (3) from the wiring harness retainer (1) on the transaxle.
12. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.5L.
13. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
14. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



15. Remove the left facia extension. Refer to Front Bumper Fascia Extension Replacement in Bumpers.
16. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
17. Remove the left tie rod end from the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
18. Remove the left ball joint from the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
19. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.




Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.

20. Remove the intermediate shaft lower pinch bolt.
21. Disconnect the intermediate shaft from the power steering gear.
22. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement in Power Steering System.



23. Remove the power steering gear mounting bolts.
24. Remove the power steering line retainers from the frame.
25. Secure the power steering gear to the exhaust manifold.



26. Remove the four nuts securing the catalytic converter to the exhaust manifold pipe.
27. Separate the catalytic converter from the exhaust manifold pipe.

Important: To prevent binding of the post catalytic converter oxygen sensor.

28. Suitably secure the exhaust system to the underside of the vehicle.
29. Remove the catalytic converter gasket. Do not reuse the gasket.



30. Loosen the two mounting nuts (2) in order to allow removal of the brake pressure modulator valve (1) from the bracket (3).
31. Remove the brake line retainers from the frame.
32. Remove the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .



33. Remove the two lower bolts and lower nut from the rear transaxle mount (1).



34. Remove the lower nut from the front engine mount.
35. Support the left side of the frame with an appropriate jack.



36. Remove the three frame-to-body bolts (3) on the left side.
37. Loosen, but do not remove, the three frame-to-body bolts (3) on the right side.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the frame.

38. Carefully lower the left side of the frame and let hang.
39. lower the vehicle enough to gain access to the engine support fixture.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the transaxle.




40. Using the engine support fixture, carefully lower the transaxle in order to allow access to the case side cover.
41. Raise the vehicle enough to gain access to the transaxle case side cover.



42. Remove the left transaxle bracket (1) from the case side cover.



43. Remove the case side cover bolts.



44. Remove the case side cover (53).
45. Clean the case and side cover gasket surfaces.

1. Inspect the case side cover (53) for the following conditions:

•	Damaged or porous gasket sealing surfaces

•	Damaged or porous casting surfaces

•	Damaged or stripped bolt holes

2. Inspect the case side cover gaskets (54, 59) for damage. The gaskets are reusable if they are NOT damaged.



3. Assemble the case side cover inner gasket (59) to the case side cover (53). Use J 36850 on the seal surfaces.
4. Install the case side cover gasket (54) and case side cover (53) onto the case. Make sure the gaskets and electrical connector are positioned correctly.



5. Install case side cover bolt (56) and one side cover to case stud bolt (58) in the locations shown. These bolts will properly locate the case side cover and gasket to the case.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the remaining bolts as indicated:

•	Nine case side cover bolts (56)

•	Four side cover TORX® head bolts (57)

•	Four side cover to case stud bolts (58)

Tighten
Tighten all bolts to 25 N·m (18 lb ft).




7. Install the left transaxle bracket (1) to the case side cover.
8. Install the left transaxle bracket bolts.

Tighten
Tighten the left transaxle bracket bolts to 110 N·m (81 lb ft).

9. Lower the vehicle enough to gain access to the engine support fixture.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when raising the transaxle.

10. Using the engine support fixture, carefully raise the transaxle to it's original position.
11. Raise vehicle.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when raising the frame.

12. Using an appropriate jack. Carefully raise the left side of the frame so that the frame-to-body bolts can be installed.



13. Using 16 mm (0.630 in) dowel pins in the alignment holes (1), align the engine frame (2) with the body.
14. Install the frame-to-body bolts (3).

Tighten
Tighten the bolts to 112 N·m (83 lb ft).

15. Install the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .



16. Install the lower nut onto the front engine mount.

Tighten
Tighten the nut to 70 N·m (52 lb ft).




17. Install the two lower bolts and lower nut onto the rear transaxle mount (1).

Tighten
Tighten the two lower bolts and lower nut to 50 N·m (37 lb ft).




18. Position the brake pressure modulator valve (1) into the bracket (3).

Tighten
Tighten the two nuts (2) to 10 N·m (89 lb in).

19. Install the brake line retainers onto the frame.



20. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

21. Position the catalytic converter onto the exhaust manifold pipe.
22. Install the four catalytic converter nuts.

Tighten
Tighten the catalytic converter nuts  to 25 N·m (18 lb ft).




23. Install the power steering gear mounting bolts.

Tighten
Tighten the bolts to 70 N·m (95 lb ft).

24. Install the power steering line retainers onto the frame.
25. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement in Power Steering System.




Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

26. Connect the intermediate shaft to the power steering gear.
27. Install the intermediate shaft lower pinch bolt.

Tighten
Tighten the bolt to 45 N·m (33 lb ft).

28. Install the drive axle into the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
29. Install the ball joint into the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
30. Install the tie rod end into the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
31. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.



32. Install the left facia extension. Refer to Front Bumper Fascia Extension Replacement in Bumpers.
33. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
34. Lower the vehicle.
35. Remove the engine support fixture.



36. Connect the transaxle electrical connector C100 (2).
37. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.



38. Install the ground cable bolt (1) onto the transaxle.

Tighten
Tighten the ground cable bolt to 17 N·m (13 lb ft).

39. Install bolt (3) to AIR pipe (2).

Tighten
Tighten bolt (3) to 23 N·m (17 lb ft).




40. Install the range selector cable bracket and cable assembly onto the transmission case.
41. Install the range selector cable bracket nuts.

Tighten
Tighten the range selector cable bracket nuts to 25 N·m (18 lb ft).

42. Install the range selector cable onto the range selector lever.
43. Check adjustment of the range selector cable. Re-adjust as needed. Refer to Range Selector Lever Cable Adjustment .



44. Install nut (5) and bolt (2) to AIR pipe.

Tighten
Tighten nut (5) and bolt (2) to 23 N·m (17 lb ft).




45. Install the throttle and cruise control cables (1) into the throttle body and the accelerator control bracket (2).
46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5L.
47. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



48. Remove the J 42640 from the steering column.
49. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications .
50. Inspect the transaxle fluid level. Refer to Transmission Fluid Check .
51. Inspect for fluid leaks.
52. Check the front end alignment.